Removable Equipment Housing for Downhole Measurements

ABSTRACT

The present invention is directed to a removable sealed housing for equipment that may be employed in obtaining downhole measurement data and methods for making same. In one illustrative embodiment, the apparatus comprises a component adapted to be positioned in a subterranean wellbore, the component having a recess formed therein, a detachable sealed housing removably coupled to the component, at least a portion of the detachable sealed housing being positioned in the recess, the housing having at least one cavity formed therein, and at least one device positioned in the cavity. In one illustrative embodiment, the method comprises positioning a detachable sealed housing at least partially in a recess formed in a component adapted to be positioned in a subterranean wellbore, removably coupling the detachable sealed housing to the component wherein at least a portion of the detachable housing is positioned in the recess formed in the component, the detachable sealed housing having at least one cavity formed therein and at least one device positioned within the cavity, positioning the component and the detachable sealed housing in the subterranean wellbore, and acquiring data using the at least one device after the detachable sealed housing is positioned within the subterranean wellbore.

STATEMENT OF RELATED CASES

The subject matter of the present application is, in a general sense,related to the subject matter disclosed in pending U.S. patentapplication Ser. No. 10/709,625, filed on May 18, 2004, entitled“Equipment Housing for Downhole Measurements,” which is herebyincorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is generally related to the field of dataacquisition related to oil and gas wells, and, more particularly, to aremovable sealed housing for equipment that may be employed in obtainingdownhole measurement data.

2. Description of the Related Art

Oil and gas wells are formed by a rotary drilling process. To that end,a drill bit is mounted on the end of a drill string which may be verylong, e.g., several thousand feet. At the surface, a rotary drivemechanism turns the drill string and the attached drill bit at thebottom of the hole. In some cases, a downhole motor may provide thedesired rotation to the drill bit. During drilling operations, adrilling fluid (so-called drilling mud) is pumped through the drillstring and back up-hole by pumps located on the surface. The purpose ofthe drilling fluid is to, among other things, remove the earthencuttings resulting from the drilling process.

The environmental conditions that exist downhole in oil and gas wellscan be very important to drilling, production and completion operations.For example, downhole temperatures and pressures as well as fluidviscosities can greatly impact various operations that are involved increating a productive oil and gas well. More specifically, with respectto drilling operations, there is a growing desire to obtain as much dataas possible regarding downhole environmental and operating conditions.Such data may be useful for research purposes, as well as, in somecases, taking actions with respect to drilling a particular well orfuture wells. Additionally, it may be desirable to provide positionalinformation, e.g., depth, and relative location of a drilling bit, suchthat a well may be properly drilled to a desired target zone.

While there are existing methodologies for acquiring some forms ofdownhole data, such methodologies tend to be relatively expensive anddifficult to employ. What is desired is a relatively low-cost mechanismand procedure for acquiring downhole measurement data. The provision ofsuch a mechanism would allow its use on a far greater number of wells,thereby providing much more information that may be useful in drillingand completing future oil and gas wells.

The present invention is directed to an apparatus and methods forsolving, or at least reducing the effects of, some or all of theaforementioned problems.

SUMMARY OF THE INVENTION

The present invention is generally directed to a removable sealedhousing for equipment that may be employed in obtaining downholemeasurement data. In one illustrative embodiment, the apparatuscomprises a component adapted to be positioned in a subterraneanwellbore, the component having a recess formed therein, a detachablesealed housing removably coupled to the component, at least a portion ofthe detachable sealed housing being positioned in the recess, thehousing having at least one cavity formed therein, and at least onedevice positioned in the cavity. In some cases, substantially all of thedetachable sealed housing may be positioned within the recess in thecomponent.

In another illustrative embodiment, the apparatus comprises a componentadapted to be positioned in a subterranean wellbore, the componenthaving a recess formed therein, a detachable sealed housing threadinglycoupled to the component, at least a portion of the detachable sealedhousing being positioned in the recess, the detachable sealed housinghaving at least one cavity formed therein, and at least one of a sensorand an electrical component positioned in the cavity.

In yet another illustrative embodiment, the apparatus comprises acomponent adapted to be positioned in a subterranean wellbore, thecomponent having a surface, a detachable sealed housing removablycoupled to the surface of the component, the detachable sealed housinghaving at least one cavity formed therein, and at least one devicepositioned in the cavity. The detachable sealed housing may be removablycoupled to the surface by use of one or more threaded fasteners.

In one illustrative embodiment, the method comprises positioning adetachable sealed housing at least partially in a recess formed in acomponent adapted to be positioned in a subterranean wellbore, removablycoupling the detachable sealed housing to the component wherein at leasta portion of the detachable housing is positioned in the recess formedin the component, the detachable sealed housing having at least onecavity formed therein and at least one device positioned within thecavity, positioning the component and the detachable sealed housing inthe subterranean wellbore, and acquiring data using the at least onedevice after the detachable sealed housing is positioned within thesubterranean wellbore.

In another illustrative embodiment, the method comprises positioning adetachable sealed housing adjacent a surface of a component adapted tobe positioned in a subterranean wellbore, removably coupling adetachable sealed housing to the surface of the component, thedetachable sealed housing having at least one cavity formed therein andat least one device positioned within the cavity, positioning thecomponent and the detachable sealed housing in the subterraneanwellbore, and acquiring data using the at least one device after thedetachable sealed housing is positioned within the subterraneanwellbore.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be understood by reference to the followingdescription taken in conjunction with the accompanying drawings, inwhich like reference numerals identify like elements, and in which:

FIG. 1 is an illustrative example of a downhole component comprising aplurality of removable sealed housings in accordance with one embodimentof the present invention.

FIGS. 2A-2C depict illustrative embodiments of a detachable sealedhousing in accordance with the present invention.

FIGS. 3A-3B depict yet another illustrative embodiment of a detachablesealed housing in accordance with the present invention.

FIGS. 4A-4B depict an embodiment of the present invention wherein thedetachable sealed housing is configured as a ring segment.

FIGS. 5A-5D depict various techniques that may be employed to attach adetachable sealed housing of the present invention to a downholecomponent.

FIGS. 6A-6C depict yet another illustrative technique for coupling adetachable sealed housing of the present invention to the downholecomponent.

FIG. 7 depicts yet another illustrative embodiment of a manner in whicha detachable sealed housing of the present invention may be attached toa downhole component.

FIGS. 8A-8B depict illustrative examples wherein a detachable sealedhousing of the present invention may be part of a nozzle employed withdownhole drill bits.

FIG. 9 depicts an illustrative example wherein a detachable sealedhousing of the present invention may be formed as part of a componentpositioned in a downhole component for various reasons.

FIGS. 10A-10C depict one illustrative embodiment of the presentinvention wherein the detachable sealed housing may be configured toreceive or send data obtained from a sensor positioned in a downholecomponent.

FIG. 11 is a view of a plurality of indicator lights and a display panelthat may be employed with various embodiments of the present invention.

FIGS. 12A-12B depict an illustrative example wherein a plurality ofdetachable sealed housings of the present invention may be employed onan illustrative drill string.

FIGS. 13A-13B depict an illustrative example wherein a plurality ofdetachable sealed housings of the present invention may be employed withwired pipe sections.

While the invention is susceptible to various modifications andalternative forms, specific embodiments thereof have been shown by wayof example in the drawings and are herein described in detail. It shouldbe understood, however, that the description herein of specificembodiments is not intended to limit the invention to the particularforms disclosed, but on the contrary, the intention is to cover allmodifications, equivalents, and alternatives falling within the spiritand scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

Illustrative embodiments of the invention are described below. In theinterest of clarity, not all features of an actual implementation aredescribed in this specification. It will of course be appreciated thatin the development of any such actual embodiment, numerousimplementation-specific decisions must be made to achieve thedevelopers' specific goals, such as compliance with system-related andbusiness-related constraints, which will vary from one implementation toanother. Moreover, it will be appreciated that such a development effortmight be complex and time-consuming, but would nevertheless be a routineundertaking for those of ordinary skill in the art having the benefit ofthis disclosure.

The present invention will now be described with reference to theattached figures. The words and phrases used herein should be understoodand interpreted to have a meaning consistent with the understanding ofthose words and phrases by those skilled in the relevant art. No specialdefinition of a term or phrase, i.e., a definition that is differentfrom the ordinary and customary meaning as understood by those skilledin the art, is intended to be implied by consistent usage of the term orphrase herein. To the extent that a term or phrase is intended to have aspecial meaning, i.e., a meaning other than that understood by skilledartisans, such a special definition will be expressly set forth in thespecification in a definitional manner that directly and unequivocallyprovides the special definition for the term or phrase.

In general, the present invention is directed to a removable sealedhousing that may be removably coupled to a downhole component that isadapted to be positioned in a subterranean hole, e.g., a wellbore. Inone illustrative embodiment, the removable sealed housing may have oneor more cavities wherein one or more devices, e.g., sensors and/orelectrical components, may be positioned in such cavities. In one veryparticular embodiment, the detachable sealed housing contains at leastone cavity wherein at least one sensor may be positioned for acquiringvarious forms of downhole data. As will be recognized by those skilledin the art after a complete reading of the present application, thepresent invention may be employed in connection with acquiring any of avariety of different types of data, and the detachable sealed housingdisclosed herein may be coupled to any of a variety of different typesof downhole components, e.g., a tubular component, a bottom holeassembly, a downhole sub, a drill bit, etc. Thus, the present inventionshould not be considered as limited to the acquisition of any particulartype of data, or as to the coupling of the detachable sealed housingdisclosed herein to any particular type of downhole component, unlesssuch limitations are expressly set forth in the appended claims. Norshould the present invention be considered as limited to use with onlysensors positioned in the cavities of the detachable sealed housing, asa variety of items or devices may be positioned in the cavities formedin the detachable sealed housing.

In general, in one illustrative embodiment, the present invention isdirected to a removable sealed housing that may be positioned, at leastpartially, in a recess or opening formed in a downhole component. FIG. 1depicts the illustrative situation where a removable sealed housing 10in accordance with the present invention may be positioned in a recess40 formed in an illustrative drill bit 14. Additionally, as depicted inFIG. 1, a removable sealed housing 10 of the present invention may bepositioned in a recess 40 formed in a tubular component 12, e.g., pipe,that is adapted to be positioned in a subterranean wellbore. The numberof detachable sealed housings 10 employed on a given downhole componentor a string of various components, e.g., a drill string, may varydepending upon the particular application.

As will be recognized by those skilled in the art after a completereading of the present application, the present invention has broadapplicability and may be employed with any of a variety of componentsthat may be positioned in a subterranean wellbore. For example, thepresent invention may be employed with drill bits, tubular components,bottom hole assemblies, drilling motors, electrical submersible pumps,fishing tools, whipstocks, packers, etc. Thus, the present inventionshould not be considered as limited to use with any particular type ofdownhole component. As will be understood after a complete reading ofthe present application, the removable sealed housing 10 of the presentinvention may take a variety of shapes and configurations, and it may beinstalled using a variety of techniques. Various illustrative exampleswill be described in the specification, however, the present inventionshould not be consider as limited to these specifically disclosedembodiments as they are illustrative in nature. Moreover, the removablesealed housing 10 may be coupled to the downhole component using avariety of techniques. Accordingly, the particular techniques disclosedherein for coupling the housing 10 to the downhole component areillustrative in nature only, and should not be considered a limitationof the present invention unless such limitations are expressly set forthin the appended claims.

FIGS. 2A-2B depict one illustrative embodiment of the detachable sealedhousing 10 in accordance with the present invention. FIG. 2A is across-sectional side view of the detachable sealed housing 10, whereasFIG. 2B is an end view of the detachable sealed housing 10. As shown inthese drawings, the detachable sealed housing 10 is generally comprisedof a body 20 having a bottom surface 19 and at least one cavity 18formed therein. The detachable sealed housing 10 depicted in FIGS. 2A-2Bfurther comprises external threads 24 and a socket 22 that will be usedto facilitate removal of the detachable sealed housing 10 from thedownhole component. One or more devices 29 may be positioned within thecavity 18 formed in the detachable sealed housing 10. The particularembodiment of the detachable sealed housing depicted in FIGS. 2A-2B hasa generally cylindrical configuration, and it is adapted to bethreadingly coupled to a downhole component (not shown) via the externalthreads 24.

In the embodiment depicted in FIGS. 2A-2C, the detachable sealed housing10 further comprises a cover plate 20 a that is threadingly secured tothe body 20 by a plurality of threaded fastners 22 a. A seal 24 a isprovided between the cover plate 20 a and the body 20 of the detachablesealed housing 10 to define at least one sealed cavity 18 in the housing10. As used herein, the term sealed housing shall be understood to meana housing comprised of at least one cavity 118 formed therein whereinthe cavity 18 is sealed to prevent the ingress of gases and/or fluidsinto the cavity 18. FIG. 2C depicts an illustrative alternativeembodiment depiction how the illustrative cover plate 20 a may besealingly coupled to the body 20 of the detachable housing 10 of thepresent invention. As shown therein, the cover plate 20 a may bethreadingly coupled to the body 20 by a threaded connection 26 a, e.g.,external threads formed on the body 20 and internal threads formed onthe cover plate 20 a. The seal 24 a is disposed between the cover plate20 a and the body 20. As will be recognized by those skilled in the artafter a complete reading of the present application, the exact manner inwhich the sealing described above may be accomplished may vary dependingon the particular application. Various illustrative examples arediscussed herein for purposes of explanation only, but they should notbe considered a limitation of the present invention.

As indicated previously, the present invention may be employed in avariety of different applications. In one illustrative example, thedetachable sealed housing 10 may have at least one device 29, e.g., atleast one sensor and/or at least one item of electrical equipment,positioned in the cavity 18. Thus, as depicted in FIGS. 2A-2B, aplurality of devices 29 are shown positioned within the cavity 18. Morespecifically, in the depicted embodiment, the devices 29 comprise aplurality of sensors 30 and a plurality of electrical components 31 thatare mounted on a surface 18 a of the cavity 18. It should be understoodthat the depicted sensors 30 and electrical components 31 are schematicand illustrative in nature. Moreover, in some cases, some of the devicesemployed in obtaining downhole data, e.g., one or more sensors, may bemounted in or on another structure, e.g., a drill bit, and the cavity 18may contain only various electrical components. In other cases, onlysensors are mounted within the cavity 18 and the electrical componentsare positioned elsewhere, e.g., a downhole sub.

The manner in which such devices, e.g., sensors 30 and/or electricalcomponents 31, are coupled together so as to obtain the desired data arewell known to those skilled in the art and thus will not be described inany greater detail herein. The sensors 30 and the electrical components31 may be mounted to the surface 18 a by a variety of known techniques,e.g., gluing, use of a potting compound, etc. Moreover, although onlythe surface 18 a is depicted as having the sensors 30 and the electricalcomponents 31 mounted thereon, such items may be mounted on any or allof the surfaces of the cavity 18 depending upon the particularapplication. Thus, the present invention should not be considered aslimited to any particular type of sensor 30 or electrical component 31or how such items are mounted within the cavity 18 of the detachablesealed housing 10 of the present invention. After the devices 29 aremounted in the cavity 18, the cavity 18 may be substantially filled witha potting compound or other material.

In general, in one illustrative embodiment, the present invention may beused to facilitate the acquisition of data regarding any of a variety ofdifferent types of downhole data or information, including, for example,formation type, well temperature, well pressure, drill bitaccelerations, velocities and displacements, drill bit inclination andazimuth, drill bit axial load and rotational torque, drill bit rotaryspeed and rate of penetration, chemical sensors for grease analysis, pHsensors, oxygen sensors, NOx sensors, carbon monoxide sensors, etc. Thepresent invention may also be employed to acquire ring compression datathat may be indicative of successful make-up. Strain gauges may beemployed in such an illustrative application. The present invention mayalso be employed to acquire data relating to drill pipe accelerations aswell as data relating to the dynamic behavior of any bottom holeassembly (BHA).

Examples of sensing devices 30 that may be positioned within the cavity18 include any of a variety of different types of mechanical and/orelectrical sensors, e.g., thermometers, gyroscopes, strain gauges,accelerometers, barometers, pressure sensors, hall effect switches, etc.Examples of electrical components 31 that may be positioned within thecavity 18 include, but are not limited to, a battery, a microprocessor,a memory unit or chip, a circuit board, a communications port, and/or ananalog-to-digital converter, etc. If desired or necessary, a pluralityof such components may be positioned within the cavity 18, e.g.,multiple batteries. The sensors 30 and electrical components 31 may becoupled together in any of a variety of known techniques.

As indicated previously, the detachable sealed housing 10 may be of anydesired shape, and any number of sealed cavities 18 may be formed withinthe housing 10. Moreover, the shape and configuration of the cavities 18may also vary depending upon the particular application. FIGS. 3A-3Bdepict another illustrative embodiment of the present invention whereinthe body 20 of the detachable sealed housing 10 has a generallyrectangular configuration and a plurality of cavities 18 are formed inthe detachable sealed housing 10. Also, in the illustrative embodimentdepicted in FIGS. 3A-3B, the cavities 18 have a generally rectangularconfiguration. As in FIGS. 2A-2C, a cover plate 20 a and seal 24 a areprovide to define the sealed housing 10 with the cavities 18 therein.

FIGS. 4A-4B depict yet another illustrative embodiment of the detachablesealed housing 10 of the present invention wherein the detachable sealedhousing 10 has a configuration of a partial ring segment. As showntherein, the body 20 comprises an inner surface 20 i, an outer surface20 o, a top surface 20 t and a bottom surface 20 b. Two illustrativegenerally rectangular cavities 18 are formed therein and are open to theinterior surface 20 i of the detachable sealed housing 10.Alternatively, the cavities 18 can open to any surface of the body 20. Aplurality of sensors 30 and electrical components 31 are positionedamong the cavities 18 formed in the detachable sealed housing 10.

In one illustrative embodiment, at least a portion of the detachablesealed housing 10 is adapted to be positioned in a recess or opening 40formed in a body 111 of an illustrative downhole component. In otherembodiments, substantially the entirety of the detachable sealed housing10 may be positioned within the recess 40. The manner in which thedetachable sealed housing 10 is coupled to the downhole component 111may vary depending upon the particular application. Again, it should beunderstood that the downhole component 111 is depicted by way of exampleonly as it may be any type of device adapted to be positioned in asubterranean wellbore. The following are illustrative examples of howthe detachable sealed housing 10 of the present invention may beremovably coupled to the downhole component 11.

As shown in FIG. 5A, in one illustrative embodiment, the detachablesealed housing 10 is a generally cylindrical component that may bethreadingly coupled to the downhole component 11. More specifically, thedetachable sealed housing 10 depicted in FIG. 5A comprises externalthreads 38 that are adapted to threadingly engage internal threads 36within the recess 40 formed in the downhole component 11. A seal 34 maybe provided between the detachable sealed housing 10 and the component111 if desired to provide redundancy with respect to preventing ingressof undesirable fluids into the cavity 18. However, since the detachablesealed housing 10 is itself sealed to prevent the ingress of fluids intothe cavity 18, the extra seal 34 may or may not be employed depending onthe particular application. A socket recess 22 is formed in the body 20of the detachable sealed housing 10 to facilitate removal of thedetachable sealed housing 10 from the recess 40. A plurality of cavities18 are formed in the body 20 of the detachable sealed housing 10depicted in FIG. 5A.

FIG. 5B depicts an illustrative situation where a split ring 50 is usedto secure the detachable sealed housing 10 within the recess 40 formedin the downhole component 11. More specifically, the split ring 50 isadapted to engage a groove 51 formed in the downhole component 11 tothereby retain the detachable sealed housing 10 in the recess 40. Asindicated above, a seal 34 may be provided between the detachable sealedhousing 10 and the downhole component 111 if desired, but it is notnecessary to practice various aspects of the present invention. As withother embodiments disclosed herein, the detachable sealed housing 10 inFIG. 5B comprises a plurality of cavities 18 formed therein.Illustrative sensors 30 and electrical components 31 are positioned inthe cavities 18.

FIG. 5C depicts yet another illustrative embodiment wherein a coverplate 60 is removably coupled to the downhole component 11 by aplurality of fasteners 52 to thereby secure the detachable sealedhousing 10 within the recess 40 defined in the downhole component 11.The number of fasteners 52 employed as well as the specific type offasteners employed may vary depending upon the particular application.In one illustrative embodiment, the fasteners 52 are threaded bolts thatare adapted to threadingly engage the downhole component 11. Similar tothe embodiments discussed previously, a seal 34 may be provided betweenthe cover plate 60 and the downhole component 11 as indicated in FIG.5C. In this illustrative embodiment, the detachable sealed housing 10comprises a single cavity 18.

FIG. 5D depicts yet another illustrative embodiment of the detachablesealed housing 10 of the present invention that may be removably coupledto a downhole component 11. As shown therein, the body 20 of thedetachable sealed housing 10 has a nose end 25 that is adapted to bepositioned in a groove 41 that forms part of the recess 40. The recess40 has a tapered surface 46 that is adapted to engage a tapered surface26 formed on the body 20 of the detachable sealed housing 10. A threadedfastener 56 having a tapered surface 57 is adapted to engage a taperedrecess 27 formed on the body 20 of the detachable sealed housing 10. Inpractice, when the threaded fastener 56 is in a retracted position, thedetachable sealed housing 10 may be inserted into the recess 40.Thereafter, by advancing a threaded fastener 56, the detachable sealedhousing 10 may be secured in the recess 40 due to engagement of thetapered surface 57 with the tapered recess 27 and the engagement of thetapered surface 26 on the detachable sealed housing 10 with the taperedsurface 46 of the recess 40. The detachable sealed housing 10 depictedin FIG. 5D comprises a plurality of cavities 18 that are open to aninterior surface 20 i of the body 20.

The present invention may also be employed in situations in which theremovable sealed housing 10 is removably coupled to a surface 11 a of adownhole component 11. The surface 11 a may be an interior surface or anexterior surface of the component 11. In one particular embodiment, thesurface 11 a may be an external cylindrical surface of the component 11.As shown in FIG. 6A, the detachable sealed housing 10 may be removablycoupled to the surface 11 a by a plurality of threaded fasteners 52 thatextend through openings 21 formed in the housing 10 and threadinglyengage the downhole component 11. In one embodiment, a plurality of suchfasteners 52 may be used to secure the detachable sealed housing 10 tothe component 11. For example, as shown in FIG. 6B, four illustrativefasteners 52 are used to secure the detachable sealed housing 10 to thecomponent 11. FIG. 6C depicts the illustrative example where a singlethreaded fastener 52 is used to secure the detachable sealed housing 10to the component 11. An additional seal 24 b may be employed in thisembodiment between the cover plate 20 a and the body 20. As indicated inFIG. 6C, the housing 10 has four illustrative cavities 18 havingcomponents 30, 31 formed therein. Of course, the configuration of thedetachable sealed housing 10 depicted in FIGS. 6A-6C is illustrative innature.

FIG. 7 depicts yet another illustrative embodiment of the presentinvention wherein the detachable sealed housing 10 is coupled to thedownhole component 11 via a hinged connection 70. More specifically, aretaining plate 72 and a plurality of fasteners 52 a, 52 b are used tosecure the body 20 of the detachable sealed housing 10 within the recess40. The threaded fastener 52 a extends through the retaining plate 72and is threadingly coupled to the component 11, whereas the threadedfastener 52 b extends through the retaining plate 72 and is threadinglycoupled to the body 20 of the housing 10.

The body 20 of the detachable sealed housing 10 may serve other usefulpurposes in addition to housing the sensors 30 and/or electricalcomponents 31. For example, in the embodiment shown in FIGS. 8A-8B, thebody 20 of the detachable sealed housing 10 is configured as a nozzle 82that is adapted to be positioned in an opening 81 formed in the body ofa drill bit 80. As will be recognized by those skilled in the art aftera complete reading of the present application, drilling mud or fluid maybe pumped down through the nozzle 82 in the direction indicated by thearrow 85. The detachable sealed housing 10 is secured within the opening81 in the drill bit 80 by a snap ring 84. In this particular embodiment,the internal surface 55 of the body 20 of the detachable sealed housing10 is configured to act as a nozzle to thereby increase the velocity ofthe drilling fluid exiting the nozzle 82. One or more cavities 18 areformed in the body 20 of the detachable sealed housing 10 as with otherembodiments of the present invention. Stated another way, the cavities18 described herein may be formed in a standard nozzle body used in thedrilling industry, and one or more devices, e.g., a sensor 30 and/orelectrical component 31, may be positioned in the cavity 18. FIG. 8Bdepicts yet another illustrative embodiment wherein the detachablesealed housing 10 is configured as a nozzle 82, and the detachablesealed housing 10 is threadingly coupled to the drill bit body 80 by thethreaded connection 86. One or more cavities 18 are formed in thehousing 10. As depicted therein, one or more cover plates 20 a are usedto cover the cavities 18 and the cover plates 20 a are secured to thedetachable sealed housing 10 by a plurality of threaded fasteners 22 b.

FIG. 9 depicts the illustrative example wherein the detachable sealedhousing 10 of the present invention is part of another componentpositioned in a downhole component. For example, as indicated in FIG. 9,the detachable sealed housing 10 may be part of a grease reservoir 90that is removably positioned within a drill bit body 80. Morespecifically, the body 97 of the grease reservoir 90 is adapted to beremovably coupled to the drill bit body 80 by a snap ring 94 that mateswith corresponding grooves 93 formed in the drill bit body 80 and thebody 97. A seal 96 is provided between the body 97 and the drill bitbody 80. The body 97 has at least one cavity 18 formed therein that isadapted to receive one or more of the sensors 30 and/or electricalcomponents 31. A threaded cover plate 20 a is used to cover the cavity18 and secured to the body 97 by a threaded connection 92. A seal 24 ais provide between the cover plate 20 a and the body 97.

The present invention may also be employed in situations when theremovable sealed housing 10 of the present invention may be adapted tocommunicate with or receive data from instrumentation, sensors and/orelectrical components that are installed in various downhole components.For example, in some applications, it may be desirable to have a sensorlocated at a particular location within a downhole component, e.g.,thermocouple positioned adjacent the bearings of a roller cutter drillbit to sense the temperature experienced by the bearings. To that end,FIGS. 10A-10C depict an illustrative example where the present inventionmay be employed in such situations. As shown in FIG. 10A, anillustrative sensor 102 is positioned in an opening 100 formed in anillustrative downhole component 11. A wire 101 extends from the sensorto a contact 104. The contact 104 is positioned such that it may beaccessed via the recess 40 formed in the component 11. In thisparticular embodiment, the removable sealed housing 10 comprises acontact ring 41 (see FIGS. 10B and 10C) formed adjacent the bottomsurface 19 of the body 20 that is adapted to engage the contact 104 suchthat data may be transmitted between and among the sensor 102 and thevarious components 30, 31 positioned in the cavity 18. The detachablesealed housing 10 may comprise one or more channels 39 having a wire 43extending from the contact ring 41 to the components 30, 31 toaccomplish such objectives. In this particular embodiment, a cover plate20 a is secured to the body 20 with a plurality of threaded fastners 22a. A seal 24 a is positioned between the cover plate 20 a and the body20.

In various embodiments of the present invention, a plurality of cavities18 are formed in the detachable sealed housing 10 and the cavities 18are connected to one another via one or more internal passageways 37(see FIG. 3A). In this illustrative embodiment, the devices, e.g.,electrical components 31 and/or sensors 30, positioned in the variouscavities 18 may be coupled to one another via wires positioned in thepassageways 37. Of course, all of the cavities 18 may not need to beinterconnected together by the passageways 37.

As illustratively depicted in FIG. 11, the detachable sealed housing 10may also be provided with one or more indicator lights and/or displaypanels for various purposes. By way of example only, FIG. 11schematically depicts an illustrative cylindrical embodiment of thedetachable sealed housing 10 with a plurality of indicator lights 47 anda display panel 42 operatively coupled to the detachable sealed housing10, e.g., positioned in an outer surface thereof. In one illustrativeembodiment, such components may be positioned such that they may beviewed by an operator looking at the outside of the detachable sealedhousing 10 or they may be positioned within one or more of the cavities18 formed in the detachable sealed housing 10. In one illustrativeembodiment, the indicator lights 47 and the display panel 42 may beviewed from the outside when the detachable sealed housing 10 isinstalled in a recess 40 formed in the component 11, such as when thedetachable sealed housing 10 is retrieved from downhole.

In the case where the present invention is employed to obtain downholedata, the indicator lights 47 and/or display panel 42 may be employed ina variety of different contexts. For example, a control logic may beestablished such that an indicator light is “on” only when a sensedparameter, e.g., temperature, pressure, torque, etc., exceeds apreselected allowable limit or range, i.e., the indicator light canindicate an out-of-tolerance or problem condition. Alternatively, thecontrol logic may be established such that the indicator light is always“on” and only goes off when an out-of-tolerance condition is sensed.Colored indicator lights may also be employed with the presentinvention, e.g., red and green lights, wherein the red light indicatedan out-of-tolerance condition and the green light indicated awithin-tolerance condition. The use of such indicator lights may be veryuseful. For example, through use of the indicator lights 47, anout-of-tolerance event may be quickly identified as soon as thedetachable sealed housing 10 is removed from the borehole. In that case,analysis of the data acquired by the devices in the housing 10, e.g.,sensors, may be given a very high priority as an out-of-tolerancecondition is indicated. Absent the use of such good/bad indicatorlights, the analysis of the acquired data may be delayed. Such delaysmay be very problematic in many situations if corrective actions aredelayed. Such indicator lights may be employed for any or all sensedvariables depending upon the particular application. The indicatorlights 47 may be LED devices that are commonly found in the industry.The lights 47 may be electrically coupled to the equipment, e.g.,electrical components 31 and/or sensors 30 positioned in the cavities 18in the detachable sealed housing 10. The lights 47 may be actuated byknown circuitry positioned within the cavities 18. The control logicused to actuate the lights 47 may be embedded in various circuits formedon the electrical components 31 positioned within the cavities 18, e.g.,a microprocessor, a programmable logic device, etc.

As indicated in FIG. 11, the detachable sealed housing 10 may also beprovided with one or more display panels 42. The display panel 42 maybe, for example, an LED display panel. The panel 42 may provideinformation with respect to one or more variables. For example, in thedepicted embodiment, the display panel displays the highest temperaturesensed during the downhole operation. Of course, the display panel 42could also indicate other variables, such as maximum downhole pressure,maximum or average torque values, etc. As with the indicator lights 47,the display panel 42 may be coupled to one or more electrical components31 and/or sensors 30 positioned in the cavities 18 formed in thedetachable sealed housing 10.

Thereafter, in the illustrative embodiment where one or more sensors 30and/or electrical components 31 are positioned within the cavities 18,the detachable sealed housing 10 is removably coupled to a downholecomponent and the detachable sealed housing 10 and the downholecomponent are positioned downhole and data is acquired regarding, forexample, various downhole environmental conditions or positionalinformation. In one illustrative embodiment, this data is stored in amemory unit or chip positioned within the cavity 18. After sufficientdata has been acquired, the detachable sealed housing 10 is broughtuphole and the information regarding the acquired data is downloaded andused for any of a variety of research, development or productionreasons. In some embodiments, the downloading of the acquiredinformation may be accomplished by an electrical connection or bywireless interrogation using a radio or infrared device. If desired, thecavity 18 may be unsealed by, for example, removing the illustrativecover plate 20 a depicted in various embodiments disclosed herein.

In some cases, the detachable sealed housing 10 of the present inventionmay be employed wherein the data obtained by the sensor(s) positionedwithin the cavity 18 is sent to the surface on a real-time, or nearreal-time, basis. To that end, a communication link between the surfaceand the sensors 30 and/or electrical components 31 within the cavity 18is provided and data is transmitted to the surface on a real-time ornear real-time basis.

FIGS. 12A-12C depict another illustrative embodiment of the presentinvention. As indicated in FIG. 12A, a plurality of removable sealedhousings 10 of the present invention may be positioned at variousspaced-apart locations along a drill string 50 having an illustrativedrill bit 14 positioned at the end thereof. In this illustrativeembodiment, the drill string 50 is comprised of many sections ofstandard un-wired pipe. In this illustrative embodiment, data may besensed by various sensors (not shown in FIG. 12A) positioned in orproximate the drill bit 14 and/or in one or more cavities 18 formed inthe detachable sealed housing 10. The detachable sealed housing 10coupled to the drill bit 14 may also contain a schematically depictedwireless transmitter 52 for transmitting data regarding the informationor parameters sensed downhole. Each of the other detachable sealedhousings 10 contain a transmitter 52 and a schematically depictedreceiver 54 that is adapted to receive wireless transmissions from thetransmitter 52 in an adjacent housing 10. In some cases, the detachablesealed housing 10 proximate the drill bit 14 may also have a wirelessreceiver 54. Thus, in this embodiment, the spaced-apart detachablesealed housings 10 may be used as relay stations to wirelessly transmitdata acquired downhole to a surface location 56. In this manner, thedata acquired downhole may be sent to the surface on a real-time ornear-real-time basis. The control circuitry and power source for thetransmitter 52 and receiver 54 may be contained in the cavities 18formed in the various detachable sealed housings 10. The plurality ofdetachable sealed housings 10 may be spaced apart any desired distancethat is consistent with reliable receipt and transmission of wirelessdata. That is, there may be multiple sections of pipe positioned betweenadjacent detachable sealed housings 10.

FIGS. 13A-13B depict yet another illustrative embodiment of the presentinvention. As shown therein, a drill string 60 is comprised of multiplesections of wired pipe 62 and a downhole device 64 positioned betweensections of wired pipe 62. Also depicted in FIGS. 13A-13B are aplurality of detachable sealed housings 10 of the present inventionremovably coupled to the wired pipe sections 62. Data wires 66 areschematically depicted in the wired pipe sections 62. As is known tothose skilled in the art, data may be transmitted along the data wires66 embedded within the wired pipe 62. To that end, the lengths of wiredpipe 62 may be provided with an inductive coil 69 on both ends of eachsection of wired pipe 62 such that data may be transmitted from onesection of pipe to another after the sections are joined together.According to this aspect of the present invention, one or more of thedata wires 66 may be operatively coupled to one or more devices 29 inthe one or more cavities 18 formed in each detachable sealed housing 10to allow data to be transmitted to or received from the sensors 30and/or electrical components 31 positioned within the removable sealedhousing 10. The manner in which the data wires 66 may be operativelycoupled to the sensors 30 and/or electrical components 31 are well knownto those skilled in the art and may vary depending upon the particularapplication. Each of the detachable sealed housings 10 may furthercomprise a wireless transmitter 52 and a wireless receiver 54 asdiscussed above with reference to the embodiment shown in FIG. 12.

In the embodiment depicted in FIG. 13A, the detachable sealed housings10 may be used to wirelessly transmit data from one section of wiredpipe 62 to another spaced-apart section of wired pipe 62. In thedepicted embodiment, the downhole device 64 is not wired, and may not becapable of being wired, e.g., a stabilizer. However, according to thisaspect of the present invention, the transmitter and receiver in each ofthe detachable sealed housings 10 may be used to bypass the un-wireddownhole device or assembly.

In general, in one embodiment, the present invention is directed to aremovable sealed housing for equipment that may be employed in obtainingdownhole measurement data. In one illustrative embodiment, the apparatusdisclosed herein comprises a component adapted to be positioned in asubterranean wellbore, the component having a recess formed therein, adetachable sealed housing removably coupled to the component, at least aportion of the detachable sealed housing being positioned in the recess,the detachable sealed housing having at least one cavity formed therein,and at least one device positioned in the cavity. In some applications,substantially all of the detachable sealed housing may be positionedwithin the recess formed in the component.

In another illustrative embodiment, the apparatus comprises a componentadapted to be positioned in a subterranean wellbore, the componenthaving a recess formed therein, a detachable sealed housing threadinglycoupled to the component, at least a portion of the detachable sealedhousing being positioned in the recess, the detachable sealed housinghaving at least one cavity formed therein, and at least one of a sensorand an electrical component positioned in the cavity.

In yet another illustrative embodiment, the apparatus comprises acomponent adapted to be positioned in a subterranean wellbore, thecomponent having a surface, a detachable sealed housing removablycoupled to the surface of the component, the detachable sealed housinghaving at least one cavity formed therein, and at least one devicepositioned in the cavity.

In one illustrative embodiment, the method comprises positioning adetachable sealed housing at least partially in a recess formed in acomponent adapted to be positioned in a subterranean wellbore, removablycoupling the detachable sealed housing to the component wherein at leasta portion of the detachable sealed housing is positioned in the recessformed in the component, the detachable sealed housing having at leastone cavity formed therein and at least one device positioned within thecavity, positioning the component and the detachable sealed housing inthe subterranean wellbore, and acquiring data using the at least onedevice after the detachable sealed housing is positioned within thesubterranean wellbore.

In another illustrative embodiment, the method comprises positioning adetachable sealed housing adjacent a surface of a component adapted tobe positioned in a subterranean wellbore, removably coupling adetachable sealed housing to the surface of the component, the housinghaving at least one cavity formed therein and at least one devicepositioned within the cavity, positioning the component and thedetachable sealed housing in the subterranean wellbore, and acquiringdata using the at least one device after the detachable sealed housingis positioned within the subterranean wellbore.

The particular embodiments disclosed above are illustrative only, as theinvention may be modified and practiced in different but equivalentmanners apparent to those skilled in the art having the benefit of theteachings herein. For example, the process steps set forth above may beperformed in a different order. Furthermore, no limitations are intendedto the details of construction or design herein shown, other than asdescribed in the claims below. It is therefore evident that theparticular embodiments disclosed above may be altered or modified andall such variations are considered within the scope and spirit of theinvention. Accordingly, the protection sought herein is as set forth inthe claims below.

1. An apparatus, comprising: a component adapted to be positioned in asubterranean wellbore, said component having a recess formed therein; adetachable sealed housing removably coupled to said component, at leasta portion of said detachable sealed housing being positioned in saidrecess, said detachable sealed housing having at least one cavity formedtherein; and at least one device positioned in said cavity.
 2. Theapparatus of claim 1, wherein said at least one device is comprised of asensor.
 3. The apparatus of claim 1, wherein said at least one device iscomprised of an electrical component.
 4. The apparatus of claim 1,wherein said at least one device is comprised of at least one sensor andat least one electrical component.
 5. The apparatus of claim 1, whereinsubstantially all of said detachable sealed housing is positioned insaid recess.
 6. The apparatus of claim 1, wherein said detachable sealedhousing is threadingly coupled to said recess.
 7. The apparatus of claim1, wherein said detachable sealed housing is removably coupled to saidhousing by a split ring.
 8. The apparatus of claim 1, further comprisinga threaded retaining member that is threadingly coupled to saidcomponent, said threaded retaining member adapted to engage at least aportion of said detachable sealed housing to secure said portion of saiddetachable sealed housing in said recess.
 9. The apparatus of claim 1,further comprising a cover plate positioned over said detachable sealedhousing, said cover plate being removably coupled to said component byat least one threaded fastener.
 10. The apparatus of claim 1, whereinsaid housing has a plurality of cavities formed therein.
 11. Theapparatus of claim 10, wherein at least one sensor is positioned in eachof said plurality of cavities.
 12. The apparatus of claim 10, wherein atleast one electrical component is positioned in each of said cavities.13. The apparatus of claim 10, wherein at least one sensor and at leastone electrical component is positioned in each of said plurality ofcavities.
 14. The apparatus of claim 1, wherein said recess is formed inan exterior surface of said component.
 15. The apparatus of claim 1,wherein said detachable sealed housing comprises; a body; a cover platecoupled to said body; and a seal positioned between said body and saidcover plate.
 16. The apparatus of claim 1, wherein said detachablesealed housing has at least one of a generally cylindrical configurationand a generally rectangular configuration.
 17. The apparatus of claim 1,wherein said detachable sealed housing has a configuration of a partialring segment.
 18. The apparatus of claim 1, wherein said detachablesealed housing is coupled to said component by at least one hingedconnection.
 19. The apparatus of claim 1, further comprising at leastone passageway extending from said at least one cavity to an externalsurface of said detachable sealed housing.
 20. The apparatus of claim10, further comprising an internal passageway formed in said detachablesealed housing that connects at least two of said plurality of cavitiesto one another.
 21. The apparatus of claim 2, wherein said at least onesensor is comprised of at least one of a thermometer, a gyroscope, anaccelerometer, a strain gauge, a barometer, a pressure sensor, a pHsensor, an oxygen sensor, a NOx, a carbon monoxide sensor, and a halleffect switch.
 22. The apparatus of claim 3, wherein said at least oneelectrical component comprises at least one of a battery, amicroprocessor, a wireless transmitter, a wireless receiver, a circuitboard, an analog-to-digital converter, a communications port and amemory chip.
 23. The apparatus of claim 1, wherein said componentcomprises at least one of a drill bit, a pipe, a motor, a rotarysteerable device, and a downhole sub.
 24. The apparatus of claim 1,further comprising at least one indicator light coupled to saiddetachable sealed housing.
 25. The apparatus of claim 1, furthercomprising at least one display panel coupled to said detachable sealedhousing.
 26. The apparatus of claim 1, wherein at least a portion ofsaid detachable sealed housing defines a nozzle that is coupled to adrill bit.
 27. The apparatus of claim 1, wherein said device isoperatively coupled to a sensor positioned within an opening defined insaid component or another component.
 28. An apparatus, comprising: acomponent adapted to be positioned in a subterranean wellbore, saidcomponent having a recess formed therein; a detachable sealed housingthreadingly coupled to said component, at least a portion of saiddetachable sealed housing being positioned in said recess, saiddetachable sealed housing having at least one cavity formed therein; andat least one of a sensor and an electrical component positioned in saidcavity.
 29. The apparatus of claim 28, further comprising a cover platepositioned over said detachable sealed housing, said cover plate beingremovably coupled to said component by at least one threaded fastener.30. The apparatus of claim 28, wherein said detachable sealed housingcomprises; a body; a cover plate coupled to said body; and a sealpositioned between said body and said cover plate.
 31. The apparatus ofclaim 28, wherein said detachable sealed housing has a plurality ofcavities formed therein.
 32. The apparatus of claim 31, wherein at leastone sensor is positioned in each of said plurality of cavities.
 33. Theapparatus of claim 31, wherein at least one electrical component ispositioned in each of said cavities.
 34. The apparatus of claim 31,wherein at least one sensor and at least one electrical component ispositioned in each of said plurality of cavities.
 35. The apparatus ofclaim 28, further comprising at least one passageway extending from saidat least one cavity to an external surface of said detachable sealedhousing.
 36. The apparatus of claim 31, further comprising an internalpassageway formed in said housing that connects at least two of saidplurality of cavities to one another.
 37. The apparatus of claim 28,further comprising at least one indicator light coupled to saiddetachable detachable sealed housing.
 38. The apparatus of claim 28,further comprising at least one display panel coupled to said detachabledetachable sealed housing.
 39. The apparatus of claim 28, wherein atleast a portion of said detachable sealed housing defines a nozzle thatis coupled to a drill bit.
 40. The apparatus of claim 28, wherein saiddevice is operatively coupled to a sensor positioned within an openingdefined in said component or another component.
 41. An apparatus,comprising: a component adapted to be positioned in a subterraneanwellbore, said component having a surface; a detachable sealed housingremovably coupled to said surface of said component, said housing havingat least one cavity formed therein; and at least one device positionedin said cavity.
 42. The apparatus of claim 41, wherein said at least onedevice is comprised of a sensor.
 43. The apparatus of claim 41, whereinsaid at least one device is comprised of an electrical component. 44.The apparatus of claim 41, wherein said at least one device is comprisedof at least one sensor and at least one electrical component.
 45. Theapparatus of claim 41, wherein said detachable sealed housing isthreadingly coupled to said surface of said component by at least onethreaded fastener.
 46. The apparatus of claim 41, wherein said surfaceof said component is an exterior surface.
 47. The apparatus of claim 41,wherein said detachable sealed housing comprises; a body; a cover platecoupled to said body; and a seal positioned between said body and saidcover plate.
 48. The apparatus of claim 41, wherein said surface is anexterior cylindrical surface.
 49. The apparatus of claim 41, whereinsaid detachable sealed housing has a plurality of cavities formedtherein.
 50. The apparatus of claim 49, wherein at least one sensor andat least one electrical component is positioned in each of saidplurality of cavities.
 51. The apparatus of claim 41, further comprisingat least one indicator light coupled to said detachable sealed housing.52. The apparatus of claim 41, further comprising at least one displaypanel coupled to said detachable sealed housing.
 53. A method,comprising: positioning a detachable sealed housing at least partiallyin a recess formed in a component adapted to be positioned in asubterranean wellbore; removably coupling said detachable sealed housingto said component wherein at least a portion of said detachable sealedhousing is positioned in said recess formed in said component, saiddetachable sealed housing having at least one cavity formed therein andat least one device positioned within said at least one cavity;positioning said component and said housing in said subterraneanwellbore; and acquiring data using said at least one device after saiddetachable sealed housing is positioned within said subterraneanwellbore.
 54. The method of claim 53, wherein substantially all of saiddetachable sealed housing is positioned within said recess.
 55. Themethod of claim 53, wherein said at least one device is comprised of asensor.
 56. The method of claim 53, wherein said at least one device iscomprised of an electrical component.
 57. The method of claim 53,wherein said at least one device is comprised of at least one sensor andat least one electrical component.
 58. The method of claim 53, whereinsaid detachable sealed housing is removably coupled to said component bya threaded connection.
 59. The method of claim 53, wherein saiddetachable sealed housing is removably coupled to said component by aretaining clip.
 60. The method of claim 53, further comprising athreaded retaining member that is threadingly coupled to said component,said threaded retaining member adapted to engage at least a portion ofsaid detachable sealed housing to removably couple said detachablesealed housing to said component.
 61. The method of claim 53, whereinremovably coupling said detachable sealed housing to said componentcomprises positioning a cover plate over said detachable sealed housing,said cover plate being removably coupled to said component by at leastone threaded fastener.
 62. The method of claim 53, wherein said housinghas a plurality of cavities formed therein.
 63. The method of claim 53,wherein said recess is formed in an exterior surface of said component.64. The method of claim 53, wherein said recess is formed in an interiorsurface of said component.
 65. The method of claim 53, wherein saidcomponent comprises at least one of a drill bit, a pipe, a motor, arotary steerable device, and a downhole sub.
 66. The method of claim 53,further comprising withdrawing said detachable sealed housing from saidwellbore and observing at least one indicator light operatively coupledto said detachable sealed housing.
 67. The method of claim 53, furthercomprising withdrawing said detachable sealed housing from said wellboreand observing at least one display panel operatively coupled to saiddetachable sealed housing.
 68. A method, comprising: positioning adetachable sealed housing adjacent a surface of a component adapted tobe positioned in a subterranean wellbore; removably coupling adetachable sealed housing to said surface of said component, the housinghaving at least one cavity formed therein and at least one devicepositioned within said at least one cavity; positioning said componentand said detachable sealed housing in said subterranean wellbore; andacquiring data using said at least one device after said detachablesealed housing is positioned within said subterranean wellbore.
 69. Themethod of claim 68, wherein said at least one device is comprised of asensor.
 70. The method of claim 68, wherein said at least one device iscomprised of an electrical component.
 71. The method of claim 68,wherein said at least one device is comprised of at least one sensor andat least one electrical component.
 72. The method of claim 68, whereinsaid detachable sealed housing is removably coupled to said surface ofsaid component by at least one threaded fastener.
 73. The method ofclaim 68, wherein said detachable sealed housing has a plurality ofcavities formed therein.
 74. The method of claim 68, wherein saiddetachable sealed housing is removably coupled to an exterior surface ofsaid component.
 75. The method of claim 68, wherein said detachablesealed housing is removably coupled to an interior surface of saidcomponent.
 76. The method of claim 68, wherein said component comprisesat least one of a drill bit, a pipe, a motor, a rotary steerable device,and a downhole sub.
 77. The method of claim 68, further comprisingwithdrawing said detachable sealed housing from said wellbore andobserving at least one indicator light operatively coupled to saiddetachable sealed housing.
 78. The method of claim 68, furthercomprising withdrawing said detachable sealed housing from said wellboreand observing at least one display panel operatively coupled to saiddetachable sealed housing.